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Avtodizel ???-238??, Руководство по эксплуатации

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154

COOLING SYSTEM 

MAINTENANCE SERVICE 

Efficient  functioning  of  the  cooling  system  has  an  impotent 

bearing on economy, dependability, service life and other performance 
factors of the engine. 

For maintenance of normal engine service do the following: 

1.

 

Fill the cooling system with special antifreeze coolants, or in 

unusual  cases  for  short  time  with  clean  soft  water.  «Hard»  water 
should be softened and settled. 

2.

 

Pour in coolant from clean containers through a funnel with 

gauze. 

3.

 

Monitor  the  coolant  temperature,  it  should  be  within         

75-90

o

C. 

4.

 

To  prevent  distortion  of  cylinder  heads  and  cylinder  block 

jackets, add coolant into a system of the hot engine gradually with the 
engine running. 

5.

 

If the cooling system is filled with water. regularly flush out 

the system of cooling with clean water from a special washing gun, if 
not  available,  with  a  strong,  preferably  pulsating  jet  of  clean  water. 
Descale the cooling system at regular intervals. 

6.

 

At  application  as  a  cooling  liquid  of  freezing  at  low  tem-

peratures  composition  “Tosol”,  periodically  watch  its  color.  If  anti-
freeze  gets  red  -  brown  painting  it  testifies  to  the  beginning  of  corro-
sion process of details of cooling system. It is necessary to replace anti-
freeze, having washed out before the cooling system (see item 5) 

7.

 

Check  frequently  the  condition  of  the  pump  impeller  gland 

seal, bearing in mind that the coolant seeping into water pump bearings 
will ruin the latter. Failure of the gland seal is symptomized by coolant 
leaking from the drain hole (fig. 72) on the pump casing; this hole must 
not be plugged. The pump with faulty gland seal remove from engine 
and send it for repairs 

8.

 

If  the  temperature  of  the  engine  is  other  than  that  stated  in 

specifications  examine  the  thermostats  and  their  gaskets.  The  main 
valve of the thermostat should start to open at 80

±

2°C (be specified on 

the thermostat body). The valve should be opened completely, moving 
on 8 mm from its seat. The faulty thermostat replace with new one. 

Содержание ???-238??

Страница 1: ...AVTODIZEL JSC Yaroslavl Diesel Engine Plant P O W E R U N I T S 238 2 238 238 2 238 Operating Instructions 238 3902150 B RUSSIA YAROSLAVL...

Страница 2: ...of power units The remarks on a design and power units run and also wishes and proposals on the contents of the present Instruction we ask to send to the address Chief Designer Department Avtodizel JS...

Страница 3: ...eration closely study the present Instruction and observe all its requests The present Instruction compiled on the basis of research work and experience of opera tion contains the necessary instructio...

Страница 4: ...rm up the engine at idle to coolant temperature 40 50o C then at small load to 75 90o C The full loading of the cold engine is not allowed It is allowed shot term about 10 minutes increase of the cool...

Страница 5: ...lants The application of the Avtodizel power units is shown in the Table The application of the units for some other equipment should be agreed with Avtodizel JSC Completeness Power Unit model and ver...

Страница 6: ...183 238 7 238 2 1 183 238 7 1322 3771 or 273 1 6582 3701 03 or 3112 3771 MAZ Trucks 238 2 2 183 238 7 1702 3771 KrAZ Trucks 238 2 3 183 238 7 1322 3771 or 273 1 238 2 5 183 40 MAZ Trucks 238 2 6 182 2...

Страница 7: ...air within minus 60 plus 50 relative humidity up to 98 at temperature 25 air dusty up 0 4 g m3 for operating in mountain conditions to the altitude 4500 m above sea level overcom ing of the pass up to...

Страница 8: ...Engine Type Four stroke turbocharged diesel engine Number of cylinders 8 Configuration of cylinders V 90 Firing order 1 5 4 2 6 3 7 8 Scheme of numbering of cylinders Crankshaft Direction of rotation...

Страница 9: ...0 1274 130 1225 125 1274 130 Speed at Maximum Torque min 1 1200 1400 1100 1300 1200 1400 1100 1300 Idle Speed min 1 maximum 2175 2275 minimum 600 50 Specific Fuel Consumption g kW h g hp h minimum 206...

Страница 10: ...fter BDC 40 31 5 40 31 5 Outlet Valves Opening degrees before TDC 66 63 66 63 Closing degrees after BDC 20 29 5 20 29 5 Number of valves per cylinder One inlet and one outlet Thermal Clearances of Val...

Страница 11: ...m Speed not less 100 1 Oil Filters Two full through one with filter element and centrifugal one with jet drive Oil cooling System With water cooled oil cooler installed on left side of cylinder block...

Страница 12: ...0 238 2 806 1111006 50 238 1 5 10 11 173 1111005 11 238 2 1 3 5 8 173 1111006 11 238 2 2 Supplying Order of Fuel Pump Sections 1 3 6 2 4 5 7 8 Speed Governor Centrifugal all mode Fuel Feed Pump Piston...

Страница 13: ...geable Filter Element for engines 238 238 Thin Cleaning With Changeable Filter Element Bypass Jet Valve is located on Filter Cover or at ability on Engine of pilot flame Pre heater Jet Valve Jet Valve...

Страница 14: ...heme Nominal Voltage 24V Alternator Alternative Currency with Belt Drive Nominal Voltage 28V Alternator Model see Section Completeness Start Device Electrical Starter of 25 3708 01 Model Nominal Volta...

Страница 15: ...ery Complete kg With separate cylinder heads without Clutch and Gearbox 1250 with Clutch 1295 with Clutch and Gearbox 1685 With one piece cylinder heads without Clutch and Gearbox 1180 1215 1180 1215...

Страница 16: ...16 Fig 2 Speed Torque Characteristics of Engines a 238 b 238 2 where N nominal power gross torque gross ge specific fuel consumption n engine speed 16...

Страница 17: ...17 Fig 3 Speed Torque Characteristics of Engines a 238 b 238 2 where N nominal power gross torque gross ge specific fuel consumption n engine speed 17...

Страница 18: ...18 Fig 4 Overall Dimensions of Power Units 238 2 238 238 2 238 18...

Страница 19: ...general engine design of 238 2 one is shown on the cross fig 5 and longitudinal fig 6 sections The design of other engines described in present Instruction similarly but can have some features Fig 5...

Страница 20: ...20 Fig 6 Engine Longi tudinal Section...

Страница 21: ...ribs tie together top and bottom plates of the cylinder part of the block providing the necessary design rigid In the cross walls of the block crankcase part are located five borings with the shells...

Страница 22: ...22 Fig 7 Scheme of installing of sealing element in metal gasket 1 metal gasket 2 push rod hole seal 3 oil drain seal 4 water inlet hole seal 5 stud seal 6 seal Fig 8 Block head and liner joint...

Страница 23: ...ers Its design similar to above described one but there absent the ring bor ings The joint of the block head and liner fig 8 is sealed with gasket of sandwich type material with metal edgings of all h...

Страница 24: ...libration of the engine and unloading of main bear ings from inertial forces of reciprocation moving masses of pistons and connecting rods and unbalanced centrifugal forces on cheeks of the crankshaft...

Страница 25: ...marked 238 1005015 30 The crankshaft is marked after punching on 5 th cheek E crankshaft journals may have two nominal dimensions and the next versions of marking are possible Crankshaft mark 238 1005...

Страница 26: ...the first crank plane The mark on the plate as point would be from outer side Twelve radial holes in the flywheel are intended for turning of the crankshaft at adjusting of the engine The access to h...

Страница 27: ...38 are equipped with the connecting rods 236 1004045 3 marked 236 1004045 2 In the small end of that connecting rod is pressed in the bush 840 1006026 10 with external diameter 54 mm Fig 10 Connecting...

Страница 28: ...r block surface of engines 238 2 238 2 1 6 035 0 065 0 mm 238 238 0 1 065 0 035 0 mm For the engines 238 238 the liners with the following design features can be installed 1 The liner 236 1002021 5 Su...

Страница 29: ...ium alloy The oil cooling of the piston is made from motionless injector On the piston skirt there is a hollow for cooling injector In the head of the piston the combustion chamber is made On the engi...

Страница 30: ...ncrease wearlessness The combustion chamber is displaced on 5 mm the lateral surface with hol low and has the excluder The height from the piston pin axis to piston top surface is increased up to 100...

Страница 31: ...the following complete sets of rings can be installed 1 Three ring complete set 7511 1004002 where First compression ring has in section a kind of a bilateral trapeze with working surface displaced do...

Страница 32: ...plated working edges and twisted spring expander Ring part number is 236 1004034 At installation of piston rings to pay special attention to correct ness of their arrangement The word Top should be i...

Страница 33: ...33 Fig 13 Piston Piston rings Piston pin At the left piston 238 1004015 4 its rings and pin At the right piston 7511 1004015 10 its rings and pin...

Страница 34: ...One piece cylinder heads T h e b a s i c v a r i a n t Bondorizated 236 1002021 5 4 ring with dense chrome With 4 grooves and niresist insert 238 1004015 4 A l l o w a b l e v a r i a n t s at repair...

Страница 35: ...s levers with adjusting screws lever shafts valves valve springs with attachment parts and valve guides fig 14 The drive of valves is carried out from camshaft through roll tappets 2 tubular push rods...

Страница 36: ...tact with push rod in tappet boring is pressed in the steel heat treated abut Tappet axles The tappets are suspended on tubular axles in stalled in borings of the cylinder block in cast iron bushes fr...

Страница 37: ...nd another in spring retainers fixed on the valve stems with the intermediate bush and two conic re tainers Presence of the bush between retainer and valve provides the turn of valves at work of the e...

Страница 38: ...38...

Страница 39: ...r shaft 3 driving shaft gear 4 housing cover 5 driven shaft gear 6 housing 7 drive gear 8 key 9 thrust flange Further through the block channels the part of oil through the valve of cooling system of...

Страница 40: ...lter element 6 hood head 7 filter element gasket 8 valve plunger 9 valve spring 10 warning device spring 11 warning device mo bile contact 12 motionless contact 13 terminal From the filter the oil goe...

Страница 41: ...ut in the central oil channel The centrifugal oil filter fig 18 is included in parallel after the full through oil filter and it cleans up to 8 of oil flow passing through lubrication system The filte...

Страница 42: ...p 3 fuel filter of thin cleaning 4 injector 5 injector spray 6 fuel feed pump 7 fuel tank From a tank through the filter of rough cleaning the fuel forces with the fuel feed pump in the filter of thin...

Страница 43: ...h pressure fuel injection pump in assembly shown in fig 20 With the high pressure fuel injection pump in one unit the speed gov ernor 5 the fuel feed pump 9 and the damper coupling 3 are incorpo rated...

Страница 44: ...with rack 16 The adjustment of uniformity of fuel delivery on the maximal mode by each section of the pump is made with turning of the section case at the loosed nuts of section fastening The change o...

Страница 45: ...g 2 lower tappet retainer 3 tappet spring 4 upper tappet retainer 5 turn bushing 6 plunger 7 plunger barrel 8 delivery valve seat 9 delivery valve 10 valve stop 11 union 12 pressing flange 13 14 gaske...

Страница 46: ...start up of the engine At screwing out of the bolt from rack the starting fuel delivery is decreased The fuel pump is oiled from the engine lubrication system under pressure The oil for the pump is s...

Страница 47: ...er 18 negative corrector lever 19 power adjusting screw 20 rack lever 21 link 22 collar 23 weight coupling 24 governor weights 25 weight holder 26 weight pin 27 driving gear 28 retainers 29 weight hol...

Страница 48: ...ves for adjust ment of nominal fuel supply In the lower part of the governor lever there are the correcting device 12 13 14 16 18 with negative cor rector intended for formation of the fuel injection...

Страница 49: ...responds At reduction of resistance to movement of the automobile the engine crankshaft speed is increased In this case centrifugal force of weights grows The weights disperse and overcoming the gover...

Страница 50: ...engine in emergencies arising at failures of turbocharger The principle of action of the supercharge fuel corrector that at de creasing of boost pressure it influences on the fuel pump rack reduc ing...

Страница 51: ...in lubrication sys tem and air in the inlet collectors is absent The spring 4 presses the piston 13 with stop 2 to the corrector case 16 The spring 11 presses the spool 12 and rod 9 with membrane aga...

Страница 52: ...ure in the membrane cavity decreases the spool 12 under action of a spring 11 is displaced to the left side and the spool end face edge blocks the piston drainage windows In the under piston cavity th...

Страница 53: ...e return corrector spring revolu tions of a beginning of operation of the corrector is adjusted with corrector case 13 fig 22 To features of adjusting it is necessary to attribute that for main tenanc...

Страница 54: ...upling 5 pointer 6 pump rack cap 7 by pass valve 8 plugs for air outlet 9 speed governor 10 supercharge fuel corrector 13 minimal speed limiting bolt 14 buffer spring body 15 shut off clamp 16 fuel fe...

Страница 55: ...he pump housing 1 are installed the plunger pairs delivery valves 10 and unions 8 to which the high pressure pipelines are con nected The delivery valve and its body precise pair which can be replaced...

Страница 56: ...w pres sure that the fuel feed pump creates in supplying channel fills the above plunger space At up wards movement of the plunger fuel is by passed in the fuel supplying channel so long as the plunge...

Страница 57: ...ED GOVERNOR The high pressure fuel injection pump is equipped with all mode speed governor 9 fig 24 mechanical direct action which changing the fuel supply depending on loading supports the engine cra...

Страница 58: ...weights coupling 23 weights pin 24 weights holder 25 driv ing gear 26 retainers 27 weights holder shaft 28 sleeve 29 rack rod 30 spring lever 31 rack lever spring The lever rack spring 31 is attached...

Страница 59: ...e steady run on the minimal idling mode The speed governor is equipped the supercharge fuel corrector for decreasing of heat intensity and smoking of the engine exhaust gases on low speeds and transfe...

Страница 60: ...dvance coupling 1 case 2 O ring 3 driving half coupling 4 washer 5 weight pin 6 driven half coupling 7 8 leap type seals 9 spacer 10 weight 11 12 adjusting washers 13 spring On the conic end of the pu...

Страница 61: ...PUMP The fuel feed pump 9 or 16 fig 20 or 24 piston type is in tended for supplying of fuel from fuel tank to high pressure fuel injec tion pump The feed pump output in 3 4 times exceeds productivity...

Страница 62: ...bushing represent the precise pair For a forcing of fuel at the not running engine the pump is equipped with the handle pump This pump is used for removal of air from fuel system before start up of t...

Страница 63: ...uel filtered through a backlash between a needle and the spray body is removed from injector through a cavity of a spring and holes in the adjusting screw and in cap 9 The injector is installed in a s...

Страница 64: ...tered through a backlash between a needle and the spray body is removed from injector through the spring cavity and hole in the injector case Fig 30 Injector 1 spray tip 2 spray tip nut 3 spacer 4 rod...

Страница 65: ...rew 10 cap 11 spring nut 12 washer 13 spring 14 bushing 15 union 16 filter The fuel to injector is supplied through the union 15 in which the bushing 14 pressing the mesh filter 16 is installed The fu...

Страница 66: ...cotton cord twisted on a mesh skeleton The filter ele ment is dense pressed on end faces between a cover and bottom of a cap The hole in the cover closed with plug 4 with and gasket 3 serves for fill...

Страница 67: ...Fuel in the filter acts through a tip 6 and a cavity in an axis 1 Clearing of fuel is carried out in settling cells of filter elements 3 par ticles of mechanical impurity and on inclined walls of cell...

Страница 68: ...3 Thin cleaning fuel filter 1 drain plug 2 drain plug gasket 3 spring 4 filter element 5 cap 6 stem 7 cap gasket 8 cover 9 plug 10 jet gasket 11 15 jet 12 bolt 13 gasket 14 filter element gasket In a...

Страница 69: ...pelines have identical length for all cylinders of the engine The ends of pipelines are punched in the form of a cone and pressed with nuts to unions of the high pressure fuel pump and injectors In or...

Страница 70: ...friction welding The turbine housing is made of heat resistant cast iron The gas enters to turbine wheel through two channels The compressor housing 4 insert and bearing housing cover 6 are made of al...

Страница 71: ...using cover 7 seal ing ring 8 compressor housing lock plate 9 bolt 10 bolt retainer 11 turbine housing lock plate 12 bearing housing 13 turbine heat reflector 14 turbine wheel and shaft as unit 15 tur...

Страница 72: ...eme of Cooling System 1 water pump 2 block water jacket 3 head water jacket 4 longitudinal water channel 5 turbocharger 6 right water pipe 7 boost air pipe 8 cooled air pipe 9 thermostatic device 10 t...

Страница 73: ...ers into radiator where gives back heat to a flow of air created by the fan 14 then backs to the water pump When temperature of a cooling liquid decreases thermostatic device automatically direct all...

Страница 74: ...ump 1 driving pulley 2 retainer ring 3 ball bearings 4 shaft 5 water slinger 6 seal ing 7 pump case 8 O ring 9 pump branch pipe 10 impeller 11 impeller plug 12 O ring 13 O ring bushing A end face seal...

Страница 75: ...ucing from 2003 year STRUCTURE AND WORK OF FAN DRIVE WITH THE SWITCH OF MECHANICAL TYPE The fan drive can work in three modes automatic one con stantly switching in and constantly switching off The fa...

Страница 76: ...8 piston ring 29 O ring 30 piston 31 piston stop 32 pressing spring When the coolant temperature will be close to the lowest opti mum level the switch stops the oil supply The oil there is under pisto...

Страница 77: ...n one of three positions 1 Position automatic 2 Position constantly switch in 3 Position constantly switch off Fig 39 Fan drive switch 1 body cover 2 back spring 3 O ring 4 washer 5 spool 6 spool spri...

Страница 78: ...tely travels in direction of moving of pusher 7 The ball 18 gets to other stopping slot spool 5 has stopped in position when oil inlet cavity is united with oil outlet cavity The oil is delivering to...

Страница 79: ...p type seal 2 cover 3 ball bearing 4 driven disk 5 driving disk 6 gasket 7 back pressed spring 8 thrust ring 9 scoop pipe 10 spacer bushing 11 piston ring 12 leap type seal 13 solenoid valve 14 case 1...

Страница 80: ...80 Fig 41 Location on engine of the fan drive parts 1 drive coupling 2 electromagnetic valve 3 oil inlet pipe 4 thermo relay Fig 42 Electromagnetic valve Fig 43 Thermo relay 32 20...

Страница 81: ...ig 45 installed in the housing The cooling oil passes of section and cooling liquid outside by counter flow In an oil cavity of the case is installed the by pass valve 1 At it opening the oil passing...

Страница 82: ...usting gasket 6 spring 7 bushing 8 seal ring 9 flange 10 gasket 11 housing 12 sections of plate ele ment 13 coupling 14 O rings On the cooler outlet pipe of the second section the drain age cock fig 4...

Страница 83: ...n with the built in rectifying unit 24 45 and the inte grated voltage regulator 120 273 1 GENERATOR DATA Rated power W 800 Rated voltage V 28 Directed currency not less 45 Rotor initial frequency of r...

Страница 84: ...3771 GENERATOR DATA Rated voltage V 28 Maximal loading currency A 45 Initial rotor speed at air and alternator temperature 25 10 and voltage 26 V rpm not more at load currency 10 A 1450 at load curren...

Страница 85: ...th run hour counter to connect with voltage regulator and starting key two terminals W tachometer wire terminal GENERATOR STRUCTURE The generator represents three phase twelve pole synchronous electri...

Страница 86: ...03 consists of the three phase synchronous generator of alternating current with the electromagnetic excitation with the built in rectifying unit 17 100 02 and the in tegrated voltage regulator 120 1...

Страница 87: ...ing unit The cover from the drive side has ventilating windows In a cover the bearing is installed The fan and the pulley are installed on the alternator shaft with key and are fixed with a nut and a...

Страница 88: ...armature 17 case 18 drive lever 19 drive 20 drive side cover 21 drive gear 22 middle bearing 23 thrust washer 24 drive case 25 leap type seal 26 rear bearing SPECIFICATION Rated voltage V 24 Rated pow...

Страница 89: ...rch arising at it warms up the intake air The structure of the device includes two glow plugs 3 fig 48 installed in the engine intake manifold 2 solenoid fuel valve 6 thermo relay with additional resi...

Страница 90: ...manufacturer 2 The sign of correspondence to the national standards with a label of organization giving the certificate 3 The sign of official proving 4 Meeting to 24R 03 Regulations 5 Meeting to 49R...

Страница 91: ...tory manufacturer are installed on the hatch of governor on the maximal idle speed adjusting bolt on the corrector cover on the power limiting screw on the upper case of high pressure fuel injection p...

Страница 92: ...5 82 of grades 40 62 at the temperature of ambient air above than minus 10 of grade from minus 35 above minus 35 of grade from minus 45 above minus 45 of grade above minus 50 For improving of ecologic...

Страница 93: ...nt air temperature 30 and above under the speci fication USA ASNM 975 81 of grade 1D Canada CAN 2 3 6 M 83 of grade TYPE At the ambient air temperature 50 and above under the speci fication of Canada...

Страница 94: ...mitcheskaya kompaniya 4126 10 2 TU 38301 13 008 97 JSC Novokuibyshevsky NPZ 4127 6 14 TU 38301 13 008 97 JSC Novokuibyshevsky NPZ SAE 15W 40 API CF 4 SG 5 14 0253 075 00148636 99 with changes 1 2 JSC...

Страница 95: ...production are recommended to applica tion with indicated viscosity class and with quality catego ries not below than CF 4 API Engine Euro 1 or CG 4 API Engine Euro 2 2 The manufacturer recommends usi...

Страница 96: ...Omsky NPZ SAE 80W 90 GL 3 TU 0253 019 00219158 95 JSC Slavneft Yaroslavlnefteorgsintez 3 18 SAE 85W 90 GL 3 TU 0253 005 57352960 02 JSC Orsknefteorgsintez SAE 80W 90 TU 0253 018 00219158 96 SAE 80W 9...

Страница 97: ...0 TU 113 07 02 88 JSC KAPROLAKTAM Dzerzhynsk town N Novgorod reg 65 TU 113 07 02 88 Next cooling liquids of foreign producers are recommended M1 E 559 USA BS 3150 Grade AL 3 England and similar All in...

Страница 98: ...0 1012040 14 Filtering element in assembly CJC Metiz Tutaev town Russia Element without packing in stalled on engine at assemble made of synthetic needle punched cloth Fuel filter of course cleaning e...

Страница 99: ...rings of tightening de vice pulley 201 GOST 6267 74 Rostovsky ONMZ Clutch releasing coupling Shaft bearing of clutch releasing fork 4 24 GOST 21150 87 Berdyansky ONMZ PO Omsknefte orgsintez Rostovsky...

Страница 100: ...ot al low leakage of fuel and oil In time clean and wipe all parts of the engine During start and engine run do not allow to it of outside per sons Do not grease adjust and wipe the running engine Dur...

Страница 101: ...fire extinguishers cover a flame with sand asbestos blanket felt or canvas Do not extinguish a flame with water At realization of electro welding works directly on the automobile with the purpose to...

Страница 102: ...eed as follows 1 Delete from the power unit preserving lubricant and clean it of a dust and dirt 2 Carry out thoroughly outer inspection of power unit and ac cessories mounted on it Make sure that the...

Страница 103: ...emperature then tight the plugs 12 By outside inspection make sure of reliable tightness of pipelines and units of lubrication fuel feed and cooling systems If necessary tighten up the joints 13 By in...

Страница 104: ...ever into the mid position To start the engine depress the starter button as soon as the engine begins to run steadily release the button The duration of con tinuous operation of the starter should no...

Страница 105: ...WHEN STARTING THE ENGINE WITH THE AID OF PILOT FLAME PRE HEATER PILOT FLAME GLOW PLUGS ARE DESIGNED FOR OPERATING VOLTAGE OF ABOUT 19V IF THE VOLTAGE IN THE PLUGS EXCEEDS 21V THEY FAIL SOON 1 Prepare...

Страница 106: ...be warmed up first at the idling speed up to 40 50 C of coolant temperature and then at a small load up to operation temperature The full load operation of the cold engine is not allowable Do not admi...

Страница 107: ...ENGINE SHUT DOWN Prior to shut down the engine should run without load at mid idling speed for 2 3 minutes To shut down the engine decrease its speed down to the mini mum and only then shut down the e...

Страница 108: ...ng liquid volume has decreased due to evaporation but not due to leakage then add only water into the cooling system as the amount of ethylene glycol remains constant owing to its high boil ing temper...

Страница 109: ...ivided into the following kinds in accordance with periodicity and list of services to be fulfilled Daily maintenance service D carried out once a day shift First maintenance service M 1 performed eve...

Страница 110: ...238 E and 238 engines lubrication system 8 Change the oil filter element If the warning signal lamp is flashing on the warmed up engine then the element is to be changed earlier than the specified ter...

Страница 111: ...t clearances 15 Carry out the adding operation on maintenance of gearbox see Gear Box Section 16 Every 3000 running hours check the easy rotation of turbo charger rotor and if necessary carry out it m...

Страница 112: ...injection advance set an gle 7 Check and if necessary adjust the tension of drive belts 8 Wash up the centrifugal oil filter 9 Check the tightening of starter attachment 10 Warm up the engine to temp...

Страница 113: ...8 mm on a short branch fig 52 A tension of the alternator drive belts check by pressing with force 40 N 4 kgf on middle of a branch of each belt fig 53 thus the belts should be sag on 10 15 mm If the...

Страница 114: ...of the alternator rod and bolt of fastening of the alternator to the rod After adjustment reliable fix the alternator At increased stretching and breakage even one of belts replace them with a comple...

Страница 115: ...cylinder head separate cylinder head ATTENTION IT IS CATEGORICALLY FORBIDDEN TO TIGHTEN NUTS WITH TORQUE MORE THAN IS SPECI FIED AS IT WILL RESULT BREAKAGE OF STUDS AND CYLINDER HEAD AND TIGHTNESS OF...

Страница 116: ...re worsened Besides the reduction of the clearance in a drive of outlet valve can result the valve overheating and damage Thermal clearances adjust on the cold engine or not earlier than 1 hour after...

Страница 117: ...urn it still approximately on 1 3 revolutions 120o This crankshaft position corresponds to the compression stroke in the first cylinder and both valves of this cylinder are closed Fig 55 Cranking of c...

Страница 118: ...ces adjusting start the engine and hear its work The knocks in the valve mechanism should not be In case of presence of characteristic knock of valves stop the engine and repeat adjusting 9 Install an...

Страница 119: ...e marks were not aligned it is necessary to make adjusting The succession of the injection advance angle adjusting of 238 2 and 238 2 engines fig 58 loosen tightness of clamp joint bolt 2 of flange 3...

Страница 120: ...injection advance angle adjusting of 238 and engines 238 fig 59 check up the fixation of half coupling 3 on the drive shaft 1 and tightness of the bolt 5 torque should be 43 2 58 9 Nm 4 4 6 kgf m scr...

Страница 121: ...he coupling with holes in the upper position and turn out the plugs At slow turn of coupling on 70 from one hole should begin to drain the oil Tight the plugs after adding of oil MAINTENANCE SERVICE O...

Страница 122: ...dations 1 Replace oil See section Maintenance Service Bearings of compressor tension device pulley 24 201 1 Fill with grease through grease fitting 500 Starter bear ings Oil used for en gine 3 Fill in...

Страница 123: ...of dust and dirt The oil priming carry out from oil dispensing columns with the dispensing gun and at absence of columns through a funnel from clean refilling container Close the filler cap Fig 60 The...

Страница 124: ...as shown in a fig 61 Fig 61 Screwing out of filter hood 2 Screw out the filter hood 5 completely and remove it fig 62 3 Press on lock cover 3 and having drowned it in the hood 5 of 2 3 mm turn on 45 t...

Страница 125: ...th the moment 20 40 Nm 2 4 kgf m 7 On the running engine to be convinced of absence of oil leak through the hood seal After the four replacements of the fil ter element replace the sealing gasket 2 WA...

Страница 126: ...tachment bolts Wash up the valves in diesel fuel without disassem bling and put them back in place If the valve is faulty broken spring etc replace the valve in assembly LUBRICATING THE COMPRESSOR DRI...

Страница 127: ...e starts oozing through the seals on the pulley rear end MAINTENANCE OF FUEL EQUIPMENT The correct and regular maintenance service of the fuel equip ment is a necessary condition of failure free runni...

Страница 128: ...our over the fuel pump of high pressure before start up by hot water During all period of operation it is forbidden the fuel pump washing with water under a pressure At a stop of the engine in the win...

Страница 129: ...at injector installation with 15 angle to a horizontal surface should not be formed coming off drop of fuel 3 The mobility of the needle check up with fuel flow through injector adjusted on the given...

Страница 130: ...clean diesel fuel At absence of tightness on a locking cone the spray tip as unit should be changed The changing of separate details of the sprayer is not allowed Injector disassembly carry out in th...

Страница 131: ...ew the nut by a hand then finally tighten it The spray nut tightening torque is 70 80 Nm 7 8 kgf m in jector union body 80 100 Nm 8 10 kgf m After assembly adjust the injector for injection beginning...

Страница 132: ...76 or lighting kerosene on TU38 401 58 10 90 having viscosity 5 6 2 s cCt at temperature 20 0 5 The temperature of fuel measured in outlet joint of the stand with pipeline to the tested pump at the c...

Страница 133: ...el with fuel is not observed Supply the compressed air to the oil outlet hole and dip the in jection pump to container with diesel fuel The high pressure fuel in jection pump is considered as airtight...

Страница 134: ...kness should be identical from both sides and the thickest gasket should be from above At increase of gaskets thickness the fuel delivery begins later at reduction earlier In order to prevent breakage...

Страница 135: ...ip from the rack lever and screw it in the spring For reduction of speed turn out the screw After that put the grip on the rack lever 5 Check up the average start fuel delivery which should be within...

Страница 136: ...f all sections divided on sections number The non uniformity of delivery on sections calculated under the formula 0 0 min max min max 100 q q q q 2 where q max maximal cycle fuel delivery mm3 cycle q...

Страница 137: ...the pump camshaft speed 650 10 min 1 supply to the corrector the oil under pressure 0 275 0 025 MPa 2 75 0 25 kgf cm2 the control lever should be on the rest in against the maximal speed limiting bolt...

Страница 138: ...etween of the piston end face and the corrector case At installation of the supercharge fuel corrector after dismantle if in it there was a necessity on the governor remove with link clamp the pump ra...

Страница 139: ...Motorpal Czechia firm Fridman Mayer and other stands of similar designs The stand should be equipped with a device for gradually changing of the drive shaft speed in the range 0 1500 min 1 a holder f...

Страница 140: ...lic medium consisting of 40 3 TU 38 101 964 83 and 60 8 TU 38 101 883 33 having viscosity from 5 up to 6 2 s t at temperature 20 5 is supposed The temperature of fuel measured in final connection of t...

Страница 141: ...e surfaces should be dry The test mode nominal the governor control lever should be rest against the maximal speed limiting bolt The fuel pressure in the pump rail should be 0 05 0 10 MPa 0 5 1 0 kgf...

Страница 142: ...Checking both adjusting of amount and uniformity of fuel de livery make in the following order 1 Check up the pressure of delivery valves opening start which should be at 1 0 0 15 MPa 10 1 5 kgf cm2 T...

Страница 143: ...inning It should be occured at speed 1065 1085 min 1 for 806 6 50 fuel pump and 1025 1045 min 1 for 807 6 50 fuel pump Measure with tachometer at the moment of rack movement start to side of delivery...

Страница 144: ...l delivery mm3 cycle q min minimal cycle fuel delivery mm3 cycle 10 Check up work of the supercharge fuel corrector for this purpose wash up in clean gasoline the union mesh filter 15 fig 23 and caref...

Страница 145: ...justed with the corrector spring body At turn in of the spring body the fuel delivery is decreased at turn out increased After adjusting safe the spring body with the nut Before replacement of the wor...

Страница 146: ...jection advancing coupling so that driven coupling bosses were installed in a horizontal position and the mark the coupling end face was in a zone of the indicator 3 Install the half coupling flange i...

Страница 147: ...ew the buffer spring body before overlapping its end face with the lock nut end face After adjusting safe the minimal speed limiting bolt and the buffer spring body with nuts The minimal idle speed ma...

Страница 148: ...ing of the bolt 5 WASHING OF THE COURSE CLEANING FUEL FILTER 1 Drain fuel from the filter 2 Unscrew four attachment bolts of filter hood 2 fig 32 to cover 7 take off the filter hood and flange 4 3 Scr...

Страница 149: ...ollowing precautions 1 Maintain the engine on speeds above idling only after nor mal pressure of oil will be established 2 Try to lower temperatures and speeds from their maximums before a stop of the...

Страница 150: ...me positions with taking up the axial play alternately in one and in the other side 3 Under no circumstances getting of dust sand or any foreign objects inside the turbocharger is to be allow 4 If the...

Страница 151: ...mature exit of the engine out of operation Normal work of the engine needs regular ser vice of the air cleaner and also the constant attention to a condition of its details is especial of gaskets and...

Страница 152: ...oot and oil are found on paper and the air blasting is considered inefficient wash the element in solution of washing de tergent 7 or 10 GOST 8433 81 in warm 40 50o C water of concentration 20 25 g of...

Страница 153: ...n the sizes of a filtering ele ment of the air filter on which place is installed the stopper Connect a compressed air source to a stopper pipe diameter 10x1 and a check tube with a valve or clamp to...

Страница 154: ...water Descale the cooling system at regular intervals 6 At application as a cooling liquid of freezing at low tem peratures composition Tosol periodically watch its color If anti freeze gets red brown...

Страница 155: ...than 6 7 h merge a spent solution and fill the system with fresh one Continue the washing during four five days After the washing ending fill the cooling system with water containing 2 g l of thrylone...

Страница 156: ...he generator installed on your power unit ATTENTION THE START UP OF THE ENGINE IS FOR BIDDEN ON THE AUTOMOBILE WITH THE GENERATOR PLUS WIRE DISCONNECTED THIS WILL CAUSE AN OVER VOLTAGE ON THE GENERATO...

Страница 157: ...should light up and after start up of the engine has gone out At M 1 without removal of the generator from the engine carry out the maintenance service in following volume 1 Check the tightness and i...

Страница 158: ...ver and stator 3 Unscrew three nuts of stator wires fastening to rectifier unit separate the stator from cover 4 Unscrew the nut of pulley fastening and remove the pulley and the fan Extract the key a...

Страница 159: ...ngine start the control lamp should light up and after start up of the engine has gone out At M 1 without removal of the generator from the engine carry out the maintenance service in following volume...

Страница 160: ...GUARANTEE ENDING IS FORBIDDEN WITHOUT EMERGENCY ANY DISASSEMBLY IS NOT RECOMMENDED Remove generator unit from the engine clean of dust and dirt and disassemble in the following order 1 Unscrew two th...

Страница 161: ...he rotor speed gradually increased until the voltage on the PV1 voltmeter will reach up to 28 V Under load test the needed load cur rent is installed on the ammeter PA after that the rotor speed is me...

Страница 162: ...e generator on the engine with the help of the voltmeter consists in the following At switched storage battery install 1500 1700 rpm en gine speed connect the voltmeter between and not painted over pl...

Страница 163: ...the slip rings end cover together with stator 4 Unscrew three fastening nuts of the stator phase terminals to the rectifier unit separate stator from cover 5 Unscrew the nut of pulley fastening and re...

Страница 164: ...g of the generator to the engine and pulley on the genera tor shaft and clean the generator of dust and dirt After every 30000 km of the vehicle run or at every second M 2 carry out maintenance servic...

Страница 165: ...holder fastening to the cover and take out the brush holder with integral voltage regulator as the unit 3 Unscrew two screws of brush holder and voltage regulator fastening to the casing 4 Unscrew th...

Страница 166: ...rent source G storage battery ammeter PV1 V3 voltmeters S1 S3 S4 switches S3 seasonal adjustment changeover switch On closing the switch S1 the field winding is supplied from an external DC 14 V volta...

Страница 167: ...hat the pin enters the hole in the bracket 3 Insert bolt 2 into the hole of the generator front lug screw it into the bracket hole without tightening the bolt The shafts of pulleys should be located i...

Страница 168: ...ely worn Brushes worn to a length of 14 mm should be re placed Measure the brush height from the point where the spring touches the lapped working surface 5 Check the tightening of the screws which fa...

Страница 169: ...and remove the drive cap 10 Extract the armature from the drive housing 11 Take the drive out of the frame 12 Remove the lever axle screws and pull the axle from the set ting holes in the frame and le...

Страница 170: ...ction of starter jumper to sole noid 3 terminal bolt for connection of storage battery to solenoid 4 indicator lamp 5 switch 6 terminal for connection of switch wire to solenoid windings Fig 79 Checki...

Страница 171: ...th clamp tighten clamp bolts with a torque of 70 90 N m 7 9 kgf m To ensure the clamp installing the connecting bus may be remove MAINTENANCE OF ELECTRIC PILOT FLAME PRE HEATER Carry out maintenance o...

Страница 172: ...tions Be sides check the pipes for air tightness with air under pressure 485 kPa 5 kgf cm2 The inside concavity of pipes should be clean Fig 80 Pintle type glow plug 1 glow pintle 2 glow plug body 3 l...

Страница 173: ...the button pushed for 30 s begin ning from the moment when the pilot lamp flashes on No leakage of fuel through the joints is permissible 8 Check the serviceability of the pilot flame pre heater elec...

Страница 174: ...condition of starter solenoid switch contacts and dress them if burnt Check brush to commutator con tact and lock for jamming of brushes in holders if necessary wipe and clean commutator and side surf...

Страница 175: ...cau tiously ENGINE LACKS POWER Clogging of air cleaner Wash air cleaner elements Obstruction of exhaust line Clogging of fuel filters Clean exhaust line Replace filtering elements Governor control le...

Страница 176: ...KNOKS Fuel injection into cylinders too early Adjust injection advance angle Valve gear out of adjustment Adjust valve to rocker clearances IRREGULAR ENGINE RUN Broken high pressure pipe or loosened...

Страница 177: ...iod of engine service Send engine to repair shop for re placing bearing shells and if neces sary for grinding crankshaft jour nals OVERHEATING OF COOLANT IN COOLING SYSTEM Before looking for cause of...

Страница 178: ...ssor cylinder head gasket Replace gasket NOISE IN TURBOCHARGER Rotor brushing against sta tionary parts Remove turbocharger for repairing or replace it AMMETER READS DISCHARGE AT RATED ENGINE SPEED Sl...

Страница 179: ...LARGE CHARGE CURRENT ammeter pointer gets over scale Faulty voltage regulator Replace voltage regulator Closure of terminal shunt wire of generator or voltage regulator on ground Eliminate closure GE...

Страница 180: ...ircuit and eliminate malfunction SOLENOID SWITCH WORKS WITH FAULTS switch in starter and immediately switches off it Storage battery discharged Charge or replace storage battery Open circuit in holdin...

Страница 181: ...t of filament in one of glow plugs Check resistance of glow plugs Replace both plugs if one of them is faulty WITH ELECTRIC PILOT FLAME PRE HEATER SWITCHED IN FOR PREHEATING AMMETER POINTER ON INSTRUM...

Страница 182: ...ealing of fuel system with pressure gauge connected Having primed fuel to a pressure at which fuel injection pump by pass valve opens make an inter val of two minutes and see that pres sure in system...

Страница 183: ...following order 1 Drain coolant from the engine cooling system 2 Disconnect all the pipes from the cylinder head and take measures to prevent dust and dirt from getting in 3 Remove the cylinder head c...

Страница 184: ...y reversing removal op erations Before installing wipe the cylinder liner shoulders and matching surfaces of the cylinder head and cylinder block with clean rags The reuse of the cylinder head gasket...

Страница 185: ...studs on a plate so as to provide a bearing surface for the valves Remove the valves with the tool illustrated in fig 84 Turn thrust screw 1 of the tool into the hole of the rocker axle stud place pre...

Страница 186: ...nd put in place It is allowed to apply the compound on the seat chamfer The process of lapping consist of recip rocating and rotating of valves with special tool in absence of such a tool use a drill...

Страница 187: ...uipped with oil cooling of pistons At dismantle of piston group on the specified engines previously take off the piston cooling injectors in order to prevent their breakages Clean the upper band of th...

Страница 188: ...nto the piston grooves To compress the rings use a mandrel fig 88 with a taper inside surface and a shoulder which allows the man drel to be accurately aligned on cylinder liner Having inserted the pi...

Страница 189: ...ngine towards the fuel injection pump In this case the hollows on the piston for the valves will be displaced concerning the centre of the cylinder in the side of exhaust collectors 5 The matching mar...

Страница 190: ...d the circumference to prevent accidental snapping out of the plugs Fig 89 Crankshaft dirt trap plugs 1 crankshaft 2 plugs INSTALLING THE CRANKSHAFT INTO ENGINE When installing the crankshaft see that...

Страница 191: ...thrust main bearing equalize the end clearance for this purpose secure the bearing cap slightly with bolts and shift the crankshaft back and forth axially to equalize the position of the cap Having ti...

Страница 192: ...ecial adaptation DISASSEMBLY AND ASSEMBLY OF FUEL INJECTION PUMP SECTION OF 806 AND 807 MODELS During repairs all possible care should be exerted to keep dust and dirt from getting inside the pump To...

Страница 193: ...ve seat 4 remove the lock screw of the plunger barrel and pull the plunger from pump housing 5 compress the spring a little and take it out of the pump hous ing complete with the upper retainer swivel...

Страница 194: ...que of 100 120 Nm 10 12 kgfm after tightening each pipe union be sure to check the rack travel Having assembled the fuel pump with governor have them ad justed on a stand DISASSENBLY AND ASSEMBLY OF W...

Страница 195: ...d washers 8 Unscrew the plug 7 from threaded hole of the impeller 2 9 Screw in threaded hole 22 1 5 of the impeller 2 the nut 17 of a remover tool 16 fig 97 98 and screwing in the bolt 18 remove the i...

Страница 196: ...ss force apply to outer bearing ring 5 Install in the housing 1 groove the circlip 9 6 Press on the shaft 5 the pulley 10 against the bear On that necessary lubricate the shaft with clean motor oil en...

Страница 197: ...less bear for opposite shaft end install the impeller on the shaft in dimension of 10 0 15 mm fig 96 between the shaft end face and impeller end face For that use at pressing the disk with diame ter n...

Страница 198: ...in the housing 1 against the bear preliminary greasing the boring in the housing 1 and ring 11 with thin lay of grease Litol 24 15 Fasten the pipe 3 with nuts 14 and washers 15 16 Check the quality of...

Страница 199: ...es ATTENTION FOR INFORMATION ON CLUTCH WITHDRAW UNIT OPERATING SEE THE INSTRUCTION MANUAL OF A VEHICLE SAFETY DEMANDS AND WARNINGS The basic condition of reliable clutch work on a vehicle is the knowl...

Страница 200: ...rictional overlay Sizes of frictional plates mm outer diameter 430 inner diameter 240 thickness 4 3 Pressure disk theoretical diameter D mm 320 Pressure spring thickness mm 5 Driven disk hub splines s...

Страница 201: ...and transmission of a torque from cover to the pressure plate For exception turning over of the diaphragm spring relatively to the cover and to pressure plate there are on the latter 6 pairs of bushes...

Страница 202: ...upling is connected through the thrust ring 4 with diaphragm spring 3 with help of the lock ing device The back moving spring 7 fig 99 excludes the turning over and axial travels of the bush 7 relativ...

Страница 203: ...ollar 5 The thrust collar 1 is installed on the diaphragm spring during assembly of the pressure plate with cover and is kept with spring washer 3 and lock ring 4 In figure the clutch release coupling...

Страница 204: ...arting up was possible minimum and the vehicle began to start up smoothly without jerks Do not allow controlling vehicle speed by the clutch slip ping the pedal is pressed partially during manoeuvring...

Страница 205: ...T UNCOMPLETELY CLUTCH DISENGAG ING OPERATION IS NOT ALLOWED The lubricant is supplied to coupling through the hose grease cup until appearance of grease in the clearance between the bearing bush and t...

Страница 206: ...tall gearbox and fix it with two bolts CAUTION AT INSTALLATING OF GEARBOX DO NOT PER MIT TRAVEL OF CLUTCH RELEASING COUPLING TO FLY WHEEL AFTER IT JOINING WITH PRESSURE SPRING 4 Move the clutch releas...

Страница 207: ...207 Fig 102 Main positions of locking device 1 thrust ring 2 spring washer 3 circlip 4 spring ring 5 lock ring 6 bearing bush 7 safety ring...

Страница 208: ...s position through the release coupling central opening 5 Turn locking collar 5 fig 102 relative to bush 6 so that collar lugs coincided with bush slots position d 6 Push the coupling to the flywheel...

Страница 209: ...fault according to vehicle opera tion manual C L U T C H N O N C O M P L E T E R E L E A S I N G Clutch drive unit does not provide necessary travel for releasing cou pling stroke Check drive unit wor...

Страница 210: ...output shaft cap has speedometer drive flange 238 5 Gear box 238 4 base For diaphragm clutch Differs by the sizes of clutch release coupling presence of clamp for gearing of coupling cylindrical back...

Страница 211: ...ft lever 238 3 Gear box 238 2 base For diaphragm clutch Differs by the sizes of clutch release coupling presence of clamp for gearing of coupling cylindrical back spring 238 4 Gear box 238 2 tightness...

Страница 212: ...anical eight gear with synchronizers of all gears except for a back moving also consists of the basic four gear box and two range planetary auxiliary transmis sion Fig 103 238 Gear Box 1 clutch housin...

Страница 213: ...213...

Страница 214: ...the rear axle distributing gear box rolling radius of wheels correspond to a vehicle speed of 25 30 km h For each concrete vehicle this value can with sufficient accu racy be determined as result of d...

Страница 215: ...the Vehicle Op eration Manual Then transfer the shift lever to a neutral position Wait and when the signal lamp will off shift the fifth gear For transition from fifth gear to fourth shift with auxili...

Страница 216: ...ansmission with speed no more than 30 km h The towage of the vehicle on the longer distance should be made by one of the following ways With drive shaft disconnected Install the control member of tran...

Страница 217: ...o output shaft speed more than 1000 min 1 SECOND MAINTENANCE SERVICE M 2 1 Carry out all operations of M 1 2 Check up and if necessary adjust a rear support of gearbox according to the Operation Manua...

Страница 218: ...walls FEATURES OF ASSEMBLY OF GEARBOX Before installation of the auxiliary transmission with spacer on casing of the basic gearbox and of the spacer on auxiliary transmission casing put on the gasket...

Страница 219: ...usting of gearbox output shaft axial play 1 centering ring 2 tight gasket 3 spacer 4 spring ring 5 adjusting gasket 6 teeth coupling Measure the dimension fig 106 from an end face of a bearing outer r...

Страница 220: ...e auxiliary transmission fastening bolts for two steps see table Tightening torques The tightening sequence according to the fig 108 At repair of the auxiliary transmission with replacement of the syn...

Страница 221: ...ting bolt from its position of bear against end face on one revolution 5 sides of the head and keeping it in this position secure it with lock nut having tightened it with torque137 157 Nm 14 16 kgfcm...

Страница 222: ...x shafts bearings worn Replace faulty bearings Gear teeth worn Replace faulty gears GEARS DISENGAGED SPONTANEOUSLY Non uniform wear of toothed sleeve teeth Replace faulty parts Gearbox shafts bearings...

Страница 223: ...Clean and grease inlet valve stem if necessary polish it Piston sealing collars of work cylinder worn or hardened Replace piston sealing collars ABSENCE OF ENGAGING OR SLOW ENGAGING OF RANGES IN AUXIL...

Страница 224: ...strictly forbidden to shift first gear at highest range engaged in the auxiliary transmission GEAR BOX CHARACTERISTICS The 239 gearbox fig 109 is mechanical nine gear con sists of the basic five gear...

Страница 225: ...225...

Страница 226: ...0 9 5 Highest 0 78 0 7 Reverse Reverse Lowest 10 04 10 04 The mechanism of auxiliary transmission range shifting is equipped with automatic blocking system of the lowest range engaging LRBS The relay...

Страница 227: ...h gear to fifth one move the auxiliary trans mission shift button for engaging of the lowest range at engaged sixth gear the vehicle velocity should be not more than 45 km h Then shift lever put in th...

Страница 228: ...iodicity of maintenance service of the engine MAINTENANCE SERVICE AFTER RUNNING IN OF THE VEHICLE After the vehicle running in period change the oil in gearbox housing clean of wearing in products the...

Страница 229: ...320 77 It is allowed the using of Litol 24 5 Clean and grease the auxiliary transmission piston seal col lars and auxiliary transmission engaging cylinder walls 6 Eliminate the leakages of air and al...

Страница 230: ...an end face of the output shaft from the gear ring end face to the bearing boring end face in the input shaft 1 3 Select the necessary number of installing gaskets proceed ing from a condition S gaske...

Страница 231: ...ect the neces sary number of installing gaskets to provide the bear of the counter shaft rear bearing end face to the spacer and the output shaft rear bear ing nestle to the teeth couple of the auxili...

Страница 232: ...es of dimensions A between end faces of teeth couple and seal gasket and between end faces of housing and bear nestle fig 114 At that the 4 5 gear synchronizer hub end face should be densely under act...

Страница 233: ...mm on a contour on the both sides of seal gasket 5 fig 105 the tightening compound UG 9 TU 6 01 1326 86 or UG 6 TU6 01 1285 84 5 Remove the special adaptation adjust axial plays in the bearings of the...

Страница 234: ...g to the bearing outside ring end face 5 4 Join to the gearbox housing the oil pump Tighten its at tachment bolts with the torque 23 5 35 3 Nm 2 4 3 6 kgfm 5 5 Check up the correctness of the counter...

Страница 235: ...of gaskets and S A Install the selected gaskets in the input shaft bearing cover boring to end face 5 9 Join the input shaft bearing cover to the gearbox housing Tighten attachment bolts with torque...

Страница 236: ...of the auxiliary transmission with replacement of the synchronizer parts adjust required rod travel at engaging f the highest range having ensured unloading of the fork retainers at operation on the...

Страница 237: ...GED WITH DIFFICULTY Incomplete clutch releasing Adjust free travel of clutch pedal or if defect is conse quence of malfunction of clutch parts replace damaged details Synchronizer worn or damaged Teet...

Страница 238: ...ing of inlet valve in pressed out position Wearing or hardening of work cyl inder seals Replace valve Replace spring Replace ring Replace damaged parts Clean and oil valve stem if necessary polish it...

Страница 239: ...lock and joints of sump gasket Locktite Ultra black Permatex Ultra black Planes of tie horizontal bolts of cylinder block main caps at installing without washers Locktite 518 Anaterm 505 Anaterm 501m...

Страница 240: ...Socket wrench 19 1 Tommy bar 1 Socket wrench 14 1 Tommy bar 1 Socket wrench 12 1 Tommy bar 1 Socket wrench 10 1 Socket wrench 24 1 Feeler gauge 1 Injector removing tool 1 Tool bag 1 Operational docum...

Страница 241: ...y of air should not exceed 70 The temperature should be supported not below 15o C Sharp fluctuations of temperature and humidity within day are not allowed The light exposure of a workplace should be...

Страница 242: ...OST 8828 89 The polyethylene film by thickness of 0 2 mm GOST10354 82 The rubberoid GOST 10923 82 The paraffined paper GOST 9569 79 The polyacrilamyde TU 7 04 01 72 The potassium chromate GOST 2652 78...

Страница 243: ...ntake duct opening 3 Drain the rests of oil from the sump and also oil from the high pressure fuel pump Drain the oil from the fuel pump through the oil outlet hole 4 Preservation of the fuel feed sys...

Страница 244: ...e high pressure fuel pump 600 ml of working preservating oil having temperature of 70 80o C through the oil outlet hole b Turn the engine downwards of cylinder head unscrew from the sump drain plug sc...

Страница 245: ...ilters 7 The preservation of the drain rail of the injectors carry out in follow order connect to the tip 10 of the drain pipe the suction strainer from special pump and dip the strainer in container...

Страница 246: ...easing the gearbox output shaft flange clutch release fork shaft and auxiliary drive hub after that put the preventive cases on the said parts grease the outer surfaces of the flywheel for the engines...

Страница 247: ...____________________ Date and sign Checked Inspector _______________________________________ Checked Inspector Term of represervation ______________________________________________________ 4 Transport...

Страница 248: ...ing temperature 70 80o C up to the top mark of the dip steak Close the oil filler cap 7 Fill the gearbox with 8 l of working preservation oil at tem perature 70 80o C Screw in the plug 8 Start the eng...

Страница 249: ...fuel delivery off position Note In case of occurrence of fire in cylinders make the preservation repeatedly meeting to the requirements 19 Drain the working preservation oil from the engine sump and t...

Страница 250: ...f the Maintenance Instruction THE SAFETY PRECAUTIONS AND FIRE PREVENTION MEASURES AT PRESERVA TION AND DEPRESERVATION 1 The preservation is made by the special workers who have received the appropriat...

Страница 251: ...pulated only the wiping with rags soaked in white spirit or gasoline 7 The amount of white spirit or gasoline on the preservation section should not exceed the day need The section should be equipped...

Страница 252: ...er cover bolts 25 32 2 5 3 2 Cylinder head stud nuts 240 260 24 26 Rocker axle nuts 120 150 12 15 Starter clamp bolt 70 90 7 9 Starter bracket bolts 45 62 4 5 6 2 Injector clamp nuts 50 62 5 6 2 Injec...

Страница 253: ...s 10 20 25 2 2 5 14 40 50 4 5 16 48 50 4 8 6 Clutch housing fastening bolts to gearbox 137 157 14 16 Clutch housing fastening bolts to flywheel housing 12 70 80 7 8 Spacer fastening bolts to basic gea...

Страница 254: ...100 POWER UNIT STARTING WORK AND SHUT DOWN 102 POWER UNIT MAINTENANCE 109 ENGINE ADJUSTMENT 113 ENGINE REPAIRING 174 FEATURES OF ENGINE DISASSEMBLY AND ASSEMBLY 183 CLUTCH 199 GEAR BOX 210 TIGHT COMP...

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